Container insert incorporating thermally insulative panels

ABSTRACT

A container insert for providing a thermally insulated enclosure. The container insert includes a bottom panel, side panels and end panels that are interconnected by a plastic backing sheet. The side panels and end panels can be pivoted upwardly to form side walls and end walls. The plastic backing sheet covers the seams between adjacent insulation panels to provide a moisture barrier. The plastic backing sheet can also urge adjacent panels together to reduce the gap between adjacent panels and improve thermal performance.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 60/911,386 entitled “CONTAINER INSERT INCORPORATING THERMALLYINSULATIVE PANELS”, filed Apr. 12, 2007, the disclosure of which isincorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the field of thermally insulatedcontainers that are adapted for the packaging, containment and/ortransport of temperature sensitive goods.

2. Description of Related Art

Insulated containers having thermally insulated walls are utilized forthe containment and/or transport of goods that can be damaged orotherwise rendered unsuitable for use if exposed to temperatures outsideof a particular temperature range. Thermal insulation can be used tomaintain a desired temperature within the container despite increases ordecreases in the exterior (ambient) temperature.

For example, the shipment of products that must have their temperaturemaintained within a specific range below ambient is one of the fastestgrowing market segments in the modern shipping industry. This growth isdriven by a number of factors including widespread concerns about safetyin the cold food distribution chain, increasing numbers ofpharmaceutical and life sciences products which must have theirtemperature maintained within certain limits, the rapid growth inhigh-value specialty chemicals such as those used in the semiconductorindustry, the increasing number of sophisticated medical tests whichrequire the shipment of patient specimens to an external laboratory, theincreased number of clinical trials associated with new pharmaceuticaldiscovery and the increased delivery of products directly to thecustomer as a result of Internet ordering.

This field is generally referred to as controlled temperature packaging(CTP). CTP can be segmented by the target temperature range, namely:frozen (below 0° C.); 2° C. to 8° C.; and less than ambient (e.g., lessthan 30° C.). In addition, CTP may be segmented by container size,namely: greater than pallet; one cubic foot to pallet; and less than onecubic foot. The one cubic foot to pallet size segment is dominated bysystems using ice (e.g., frozen gel packs) and/or dry ice as a coolantwhere the containers are insulated using expanded polystyrene (EPS). Themarket segment for containers less than about one cubic foot in size iscurrently very limited due to the need for a small, lightweight coolingmechanism and due to the need to use relatively thin insulating walls tomaximize the available space for the product cavity.

A relatively simple thermally-insulated container system includes acardboard box into which EPS sheets have been cut and placed. Thecontainer is then filled with dry ice in which, for example, frozen fishis shipped. A more sophisticated approach is a validated systemconsisting of custom molded EPS forms in a rigid box with both frozenand warm gel packs, the combination of which has been tested through arange of temperature cycles for specified thermal properties. Such avalidated system can be used for shipping pharmaceuticals, or for longduration or high-value shipments. For example, many pharmaceuticalproducts such as vaccines and antibodies must be maintained within atemperature range of 2° C. to 8° C.

The high cost of shipping is at least partially related to the volumeoccupied by the EPS insulation. For a one cubic foot box with a 60 hourlifetime at 2° C. to 8° C., over 90 percent of the container volume isoccupied by EPS and gel packs.

Some reduction in volume and therefore shipping costs may be obtained byusing vacuum insulation panels (VIPs) as the thermally insulatingmaterial. VIPs have a high thermal resistance; however, they are muchmore costly than EPS sheets. Therefore, to be economically competitive,VIPs should be provided in a manner that the VIPs can be readily usedmultiple times.

When utilizing a container or similar article that is insulated withVIPs, the highest potential for thermal losses from the container occursat the edges and corners where two VIPs are in contact. Having aninadequate seal along these edges can severely degrade the performanceof the thermally-insulated container. Sealing the edges of adjacent VIPscan be difficult since the standard manufacturing method for VIPsinvolves evacuating the panel and sealing one or more of the paneledges, which results in a flap protruding from the edge. The presence ofsuch a flap can inhibit gap-free mating between adjacent panels.

U.S. Pat. No. 7,140,508 by Kuhn et al. discloses a shipping box forshipping high-value objects such as framed paintings, where the walls ofthe shipping box can be lined with VIPs. To avoid thermal bridges and adecrease in performance, multiple layers of VIPs can be used where thejoints between adjacent VIPs in one layer are offset relative to thejoints in an underlying layer. It is also disclosed that the edge flapsof the VIPs should not be located in the area in which adjacent VIPstouch, such as along the edge of the panel.

U.S. Pat. No. 6,244,458 by Frysinger et al. discloses VIPs where thebarrier film is provided as a sheet material with edges that are sealedtogether. The edges are joined together over a sealed portion thatextends for ½ inch or more from the underlying edge surface, such thatthe VIP does not have a smooth, uniform outer profile. Accordingly,adjacent vacuum panels cannot be positioned without space between them.Therefore, Frysinger et al. provide a compressible layer of thermalinsulation wrapped around each of the VIPs. It is disclosed by Frysingeret al. that the presence of the compressible insulation layer can reducethermal edge losses.

U.S. Pat. No. 6,220,473 by Lehman et al. discloses a soft-sidedcollapsible insulative container having a base, peripheral sidewallsextending from the base, and a lid. Each of the base, lid and sidewallsare formed of a sealable pocket having a compressible insulation lining.Each pocket is adapted to contain a piece of block insulation tothermally insulate the container. A flexible fabric casing extendstightly around the container in the fully closed position to exertuniform pressure on the container.

Standard insulation materials, including the compressible insulationdisclosed by Frysinger et al. and Lehman et al., do not provide thethermal resistance of VIPs, and will inherently contribute to thermallosses in a container that is otherwise lined with VIPs. There remains aneed for a thermally-insulated shipping container system having improvedthermal performance.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide athermally insulative container insert that is adapted to be placedwithin a container, such as a shipping container. The insert can beplaced within an outer container, such as a cardboard box, to providethermal insulation for a product placed within the container. The insertcan advantageously reduce the amount of manual labor previously requiredto thermally insulate a container, particularly when using vacuuminsulation panels. The insert can also minimize or eliminate the gapsthat can exist between adjacent insulation panels to increase thermalperformance by reducing thermal bridging and reducing the formation ofcondensation, or the formation of ice in frozen applications. For dryice shipments in particular, ice can form within the container andincrease the heat load, serve as a thermal bridge and can push adjacentpanels apart. The present invention can reduce or eliminate theformation of ice by providing a tightly sealed and thermally insulatedproduct cavity.

In one embodiment, a container insert for thermally insulating acontainer is provided. The insert includes a base insulation panelhaving a top surface, a bottom surface and a peripheral edge surface.First and second side insulation panels are provided each having a topsurface, a bottom surface and a peripheral edge surface. The side panelsare attached to the base panel in spaced-apart relation on oppositesides of the base panel by a plastic backing sheet. First and second endinsulation panels are also provided each having a top surface, a bottomsurface and a peripheral edge surface. Each of the end panels isattached to the base panel in spaced-apart relation on opposite ends ofthe base panel by a plastic backing sheet. Each of the side panels andthe end panels can be pivoted upwardly toward the base panel to contactthe base panel along a seam and form side walls and end walls. Theplastic backing sheet covers at least a portion of each of the seamsbetween the base panel and the side panels and between the base paneland the end panels to form an enclosure having a base, side walls andend walls and a top opening.

In another embodiment, a container insert includes a base insulationpanel having an interior surface, an exterior surface and a peripheraledge surface. First and second side insulation panels are transverselydisposed at opposite sides of the base panel to form side walls, whereeach side panel has an interior surface, an exterior surface and aperipheral edge surface. First and second end insulation panels aretransversely disposed at opposite ends of the base panel to form endwalls, each end panel having interior surface, an exterior surface and aperipheral edge surface. A plastic backing sheet is disposed around atleast a portion of the exterior surfaces of the base panel, side panelsand end panels. The plastic backing sheet covers at least a portion ofeach of the seams between the base panel and the side panels and betweenthe base panel and the end panels, and covers at least a portion of eachof the seams between adjacent side panels and end panels, such that theplastic backing sheet urges adjacent panels together along the seams.

DESCRIPTION OF THE DRAWINGS

FIG. 1( a) and 1(b) illustrate a thermal insulation panel that is usefulin the container insert of the present invention.

FIG. 2 illustrates a top view of a container insert according to anembodiment of the present invention.

FIG. 3 illustrates a top view of a container insert in apartially-assembled state according to an embodiment of the presentinvention.

FIG. 4 illustrates a top view of a container insert in apartially-assembled state according to an embodiment of the presentinvention.

FIG. 5 illustrates a top view of a container insert in an assembledstate according to an embodiment of the present invention.

FIG. 6 illustrates a perspective view of a container insert in anassembled state according to an embodiment of the present invention.

FIGS. 7( a) and 7(b) illustrate cross-sectional views of vacuuminsulation panels according to an embodiment of the present invention.

DESCRIPTION OF THE INVENTION

The present invention is directed to a container insert and a method forusing the container insert to thermally insulate products containedtherein. In this regard, the container insert includes thermallyinsulative panels that form the walls of the container insert.

FIGS. 1( a) and 1(b) illustrate a thermally insulative panel that can beutilized in the container insert. The thermally insulative panel 1 ispreferably rigid such that the panel can form a rigid wall of thecontainer insert. The panel 1 includes a top surface 2 and a mutuallyopposed bottom surface 6. The thermal insulation panel also includes aperipheral edge surface 4 extending along the perimeter of theinsulation panel 1. In one embodiment, the peripheral edge surface 4 canhave a thickness of from about ¼ inch to about 2 inches.

In one particularly preferred embodiment, the insulative panel 1 is avacuum insulation panel (VIP). In this regard, the insulative panel 1includes a thermally insulative core material 8 surrounded by a barrierfilm 9. The barrier film 9 is preferably a polymer barrier film tofacilitate heat welding of the panel 1 to a plastic backing sheet, as isdescribed below.

A container insert according to an embodiment of the present inventionis illustrated in FIGS. 2-5, which each illustrate a top-view of thecontainer insert 10 in various stages of assembly. The insert 10 isillustrated in FIG. 2 in the fully flat and unassembled configuration,before assembly by a user (e.g., a shipper) and placement into an outercontainer, such as a cardboard box. It is a significant advantage thatthe container insert 10 can be shipped to a user in this flatconfiguration and assembled by the user when needed to store ortransport temperature sensitive goods.

The insert 10 is adapted to be assembled and form a thermally insulatedbottom wall, side walls and end walls to define a thermally insulatedproduct cavity. The product can be inserted through a top opening, andthen a thermally insulated lid panel can be placed over the top openingto provide a thermally insulated product cavity.

Referring to FIG. 2, the insert 10 includes a base insulation panel 12,a first side insulation panel 14, a second side insulation panel 16, afirst end insulation panel 18 and a second end insulation panel 20.Although the various panels and walls of the insert 10 are described asbeing disposed on the bottom, side and end of the container insert, theinsert can be utilized in various orientations and such terms are notintended to be limiting in this regard. For example, each of theinsulation panels could be a square panel of equivalent dimensions.

Each of the panels is thermally insulative panel, for example apolyurethane panel, an expanded polystyrene panel or the like. Accordingto one embodiment, the thermally insulative panels comprise vacuuminsulation panels (VIPs). VIPs utilize the insulative effects of anear-vacuum to provide a high thermal resistance, and can provide suchhigh thermal resistance at reduced thicknesses as compared toconventional insulation, such as EPS, thereby increasing the usefulinternal volume (e.g., the product cavity) of a container lined with theinsulative panels. VIPs are disclosed in more detail below with respectto FIGS. 7( a) and 7(b).

According to the present invention, the insulation panels areinterconnected by a plastic backing sheet 26 that is attached to thebottom surface of each insulation panel. For example, the backing sheetcan be heat welded to the bottom surface of each of the insulationpanels. The end panels and side panels are attached to the plasticbacking sheet 26 in spaced apart relation to the base panel 12 in amanner that they can be pivoted upwardly toward the base panel to formside walls and end walls of the container insert. Although describedherein as one contiguous plastic backing sheet, the backing sheet cancomprise two or more individual and separate portions, so long as thebacking sheet connects the base panel to the side panels and end panelsin the manner described herein.

The plastic backing sheet 26 can perform several functions in theassembled container insert 10, including covering and sealing of theseams where adjacent insulation panels are in contact and facilitatingthe compression of the adjacent panels along the seams to reduce oreliminate gaps between adjacent panels. In this regard, it should benoted that adjacent insulation panels are in direct contact when theinsert is assembled, as opposed to having a material layer disposedtherebetween. The plastic backing sheet 26 is preferably vaporimpermeable, particularly with respect to water vapor to provide acondensation barrier between the product cavity and the outsideenvironment. The plastic backing sheet 26 can also provide abrasionresistance to the exterior surfaces of the container insert 10.

The plastic backing sheet 26 can comprise a single layer of a plasticmaterial, preferably a thermoplastic material such as polyethylene (PE).More preferably, the plastic backing sheet 26 is a multilaminatematerial comprising two or more layers of plastic materials to providemultiple functionalities. For example, the plastic backing sheet cancomprise two layers of PE, with a layer of a material disposedtherebetween, such as a polyamide layer (e.g., Nylon) or a polypropylene(PP) layer.

The end panels 18 and 20 are attached to the plastic backing sheet 26 atopposite ends of the base panel 12. The end panels 18 and 20 arespaced-apart from the base panel 12 by a distance that is approximatelyequal to the thickness of the base panel 12, with a portion of thebacking sheet 26 being disposed between the end panels and the basepanel 12, preferably along the entire edge of each end panel that isadjacent to the base panel. In one embodiment, the base panel 12 is aVIP having a thickness of at least about ¼ inch and up to about 2inches, and therefore the distance between the end panels and the basepanel can also be from about ¼ inch to about 2 inches. In this manner,when the end panels are pivoted upwardly and toward the base panel toform end walls (FIG. 3), the portions of the backing sheet 26 disposedbetween the base panel 12 and the end panels 18 and 20 forms a tightseal along the bottom horizontal seams where the end panels contact thebase panel 12.

The plastic backing sheet 26 can also include linear perforations 28 a,28 b, 28 c and 28 d extending outwardly from the opposed edges of theend panels 18 and 20 toward the base panel. The backing sheetperforations facilitate the pivoting of the end panels toward the basepanel 12 to form end walls without moving the side walls. The backingsheet perforations can be, for example, scores in the sheet to enablethe sheet to be easily separated, or can be a cut directly through thesheet 26.

Side panels 14 and 16 are disposed on opposite sides of the base panel12 in spaced-apart relation to the base panel. As with the end panels, aportion of the plastic backing sheet 26 is disposed between the sidepanels and the base panel, preferably along the entire edge of thepanels that is adjacent to the base panel. The spacing between the basepanel 12 and the side panels 14 and 16 is preferably about equal to thethickness of the base panel 12 to facilitate the formation of a tightseal along the lower seams of the side panels when they are pivotedupwardly toward the base panel to form side walls.

As illustrated in FIG. 2, the insert 10 also includes means to securethe backing sheet 26 around the exterior walls of the container insert,that is, around the exterior surfaces (outside the product cavity) ofthe end panels and side panels. In this regard, the plastic backingsheet 26 extends beyond the opposed side edges of the side panels 14 and16. In this manner, when the end panels are pivoted upwardly and theside panels are then pivoted upwardly, that portion of the backing sheetextending beyond the edges of the end panels can be wrapped around theexterior surface of the panels and can be attached to the end panels.

In the embodiment illustrated in FIG. 2, the attachment means includeshook and loop fasteners having hook portions 22 b and 24 b attached tothe plastic backing sheet 26, and loop portions 22 a and 24 a attachedto the bottom surface of the end panels.

FIG. 3 illustrates a top-view of the partially-assembled containerinsert 10, namely where the end panels 18 and 20 have been pivotedupwardly and toward the base panel 12 to form end walls for thecontainer insert 10. The portion of the backing sheet 26 disposedbetween the base panel 12 and the end panels 18 and 20 thereby forms atight seal along the entire seam where the peripheral edge surface ofthe end panels and the top surface of the base panel are in directcontact. This advantageously reduces the permeation of water vapor intothe product cavity and hence reduces condensation of water vapor whenthe interior product cavity of the container insert 10 is at a reducedtemperature.

FIG. 4 illustrates a top view of the partially assembled containerinsert 10. Compared to FIG. 3, the side wall panels 14 and 16 have beenpivoted upwardly and toward the base panel 10 to form side walls for thecontainer insert 10. As with the end panels, the portion of the backingsheet 26 disposed between the side panels and the base panel 12 forms atight seal along the seam where the base panel and side panels are incontact to reduce the permeation of water vapor into the product cavity.

When the side panels are pivoted and placed on the base panel 12 to formside walls, it can be seen that a portion of the backing sheet 26extends away from opposite ends of each side panel and each such portionof the backing sheet 26 includes a hook portion 22 b/24 b of a hook andloop fastener. In this regard, these portions of the backing sheet canbe pulled tightly and attached to the back side of the end panels 18 and20 which have loop portions 22 a/24 a adapted to attach to the hookportions 22 b/24 b. When the backing sheet 26 is pulled tightly in thismanner, the backing sheet 26 urges the seams between the end panels andside panels together to reduce or eliminate any gaps between the panelsand thereby improve the thermal performance of the container insert.

Other means and methods of attaching the backing sheet 26 so that itsecurely and tightly wraps around the periphery of the insert 10 andsecures the panels can be used. For example, the backing sheet 26 can beattached by heat welding the backing sheet to the external surface ofthe end panels, which can also include a plastic material. However,temporary fasteners such as hook-and-loop fasteners provide theadvantage that the insert can be easily disassembled and re-used.

A top view of an assembled container insert 10 is illustrated in FIG. 5.It can be seen that the plastic backing sheet 26 is wrapped tightlyaround the exterior of the side walls and end walls and is attached tothe end panels by hook and loop fasteners 22 and 24. This provides atleast two advantages—the plastic sheet compresses the panel edgesagainst each other to form a tight seal along the vertical edges betweenpanels, and the plastic material of the backing sheet 26 provides abarrier to prevent penetration of water vapor or other gases into theproduct cavity defined by the insert. It will be appreciated that whilethe backing sheet perforations 28 facilitate pivoting of the end panels18 and 20 to form end walls (FIG. 2), such perforations should not alsobe included with respect to the side panels, as this would preclude theability to tightly wrap the backing sheet 26 around the periphery of thecontainer insert 10. However, seams could extend from the edges of theside panels, in lieu of those illustrated in the figures extending fromthe end panels.

FIG. 6 illustrates a perspective view of an assembled container insert10. The insert 10 includes a base insulation panel 12 as well as sidewalls and end walls. The end walls are formed by the first endinsulation panel 18 and the second end insulation panel 20. The endpanels are transversely disposed on the base panel at opposite ends ofthe base panel to form the end walls. Similarly, the side walls areformed by a first side insulation panel 14 and a second side insulationpanel 16 which are also transversely disposed on the base panel atopposite sides of the base panel 12. By virtue of this assembly,horizontal seams exist where the side panels and end panels contact thebase panel and vertical seams exist where the adjacent side panels andend panels are in contact. For example, horizontal seams 13 a and 13 bare formed between the base panel 12 and each of the side wall 16 andthe end wall 20. Similarly, vertical seams 20 a and 20 b form betweenthe end panel 20 and the two adjacent side panels 14 and 16. The backingsheet 26 advantageously covers these seams and urges (compresses) thepanels together to reduce any gap between the panels.

A lid 30 can be placed on the insert to seal the top opening. The lidcan include, for example, an insulation panel 32 of a size and typesimilar to the base panel 12. A piece of foam 34 such as polyethylenefoam or a similar material can be placed on top of the insulation panel32 so that the bottom surface of the insulation panel 32 is compressedagainst the top edge surfaces of the side panels and end panels when thetop lid of a container is closed and pressed against the foam 34.

As is discussed above, the thermal insulation panels (e.g., panels 12,14, 16, 18 and 20) can comprise vacuum insulation panels (VIPs).Cross-sectional views of VIPs are illustrated in FIGS. 7( a) and 7(b).Referring to FIG. 7( a), the VIP includes a core material 44 a and abarrier film 42 a disposed around the core material 44 a. During themanufacturing process, the core material 44 a can be pressed into thegeneral shape of the panel (e.g., a rectangular shape) which is placedinto an envelope of the barrier material 42 a. The barrier materialenvelope is then evacuated and sealed to form a rigid VIP.

The core material provides structural strength to prevent the panelwalls from collapsing and to provide heat transfer resistance, and a gasimpermeable barrier film surrounding the core material that is sealedafter a near vacuum is achieved inside the panel. The vacuum insulationpanel is evacuated to a low pressure, such not greater than about 100mbar (about 75 torr), or less.

The core material can comprise a variety of materials, such as open cellpolyurethane or polystyrene foam (e.g., INSTILL, available from the DowChemical Company). According to a preferred embodiment, the corematerial is a particulate material, such as silica, titania and/orcarbon. The particulates can form a branched network of primaryparticles which aggregate into larger particles. Preferably, the corematerial has pore sizes ranging from about 10 nm to about 100 nm. TheVIPs can also include getter or desiccants within the panel that areadapted to adsorb residual gases and moisture, which increases theuseful lifetime of the panels.

The barrier film 42 a is a substantially gas-impermeable material thatcan be sealed at the edges to form an envelope for the core material.The barrier film can be a laminate film that includes a metallic layerand at least one plastic layer, such as a laminate that includes ametallic layer sandwiched between two plastic layers. However, barrierfilms that include a metallic layer can be disadvantageous in thecontainer insert since the metallic layer can serve as a thermal bridgeat the edges of the insert, reducing the thermal performance of theinsulation. Further, metallized layers are subject to stress cracking,which also can reduce thermal performance.

It is therefore preferred that the barrier film does not include ametallized barrier. In this regard, the barrier film can include a firstplastic film layer, preferably a thermoplastic layer, on the internalsurface so that the inner layer of the barrier film can be heat sealedafter evacuation of the panel. It is also preferred that the barrierfilm include an outer layer that is also fabricated from a plasticmaterial, such as PE, to enable heat welding of the panels to theplastic backing sheet of the container insert. According to oneembodiment, the barrier film comprises a multi-layer coextrudate whichis not susceptible to stress cracking. For example, the coextrudate caninclude a layer of PE and a layer of ethylene vinyl alcohol (EvOH), witha layer of a material such as polyamide (e.g., Nylon) or polyethyleneterephthalate (PET) disposed therebetween. The EVOH layer can provide anoxygen barrier and the polyamide or PET can provide toughness, e.g.,abrasion resistance. Other layers could include polyvinylidene chloride(PVDC) or a similar material for a moisture barrier.

These plastic barrier film materials can be made, for example, bycoextrusion or lamination. Pigments can also be added to one or more ofthe various layers for aesthetic purposes, i.e., so that the corematerial is not visible to the user. In this regard, the plastic barrierfilm can also be comprised of different colors to indicate differentproperties, such as the thickness of the panel. The barrier film canhave a thickness, for example, of at least about 60 micrometers and notgreater than about 200 micrometers.

Referring to FIG. 7( a), the sealing process to form the VIP typicallyresults in the formation of at least two flaps 46 a and 48 a alongopposite edges of the panel 40 a. Depending upon the laminate materialsused in the barrier film 42 a and the desired pressure within the panel,it may be desirable to have an extended flap such as those illustratedin FIG. 7( a) to ensure that an adequate seal is formed along the edgesof the panel.

These flaps 46 a and 48 a can inhibit the formation of a tight seal ininsulated containers when that peripheral edge surface of the panelpresses against an adjacent panel. This has often required the end-userto manually tape the flap down or take other measures to ensure anadequate seal.

According to the present invention, the flap 46 a/48 a can be bent andsealed to the surface of the panel. FIG. 7( a) illustrates the flapsbeing pressed against the top surface of the panel 40 a and attached tothe surface, such as by using heat and pressure. In this regard, if thebarrier material 42 a has a plastic outer film, the film can be heattreated under modest pressure to adhere the flap to the surface of thepanel.

FIG. 7( b) illustrates an alternative embodiment of a VIP including acore material 44 b wherein the flaps 46 b/48 b are shorter than theflaps illustrated in FIG. 7( a) and are bent back and attached to theperipheral edge surface of the panel 40 b.

The container insert according to the present invention advantageouslyprovides thermally insulated side walls, end walls and a thermallyinsulated base. After a product is placed into the cavity defined by theside walls, end walls and base by inserting the product through the topopening, a thermally insulated lid such as a VIP panel can be placedover the opening to completely surround the product with thermalinsulation. The container insert and lid can all be placed within anouter container, such as a cardboard box, which is then sealed forstorage or shipment of a product. For example, the top lid can rest uponthe top edges of the side walls and end walls. A layer of a foammaterial, such as polyethylene foam, can be placed on top of the lid(e.g., beneath the outer cardboard lid) to provide uniform compressionupon the lid when sealed in the container to facilitate the formation ofa tight seal. In one embodiment, the lid can also be attached to thebacking sheet in a manner that the lid hinges and pulls down to seal ina manner similar to the end panels and side panels.

While various embodiments of the present invention have been describedin detail, it is apparent that modifications and adaptations of thoseembodiments will occur to those skilled in the art. However, is to beexpressly understood that such modifications and adaptations are withinthe spirit and scope of the present invention.

1. A container insert, comprising: a base insulation panel having a topsurface, a bottom surface and a peripheral edge surface; first andsecond side insulation panels each having a top surface, a bottomsurface and a peripheral edge surface, where the side panels areattached to the base panel in spaced-apart relation on opposite sides ofthe base panel by a plastic backing sheet; first and second endinsulation panels each having a top surface, a bottom surface and aperipheral edge surface, where the end panels are attached to the basepanel in spaced-apart relation on opposite ends of the base panel by aplastic backing sheet; wherein each of the side panels and the endpanels can be pivoted upwardly toward the base panel to contact the basepanel along a seam and form side walls and end walls, wherein theplastic backing sheet covers at least a portion of each seam between thebase panel and the side panels and between the base panel and the endpanels, to form an enclosure having a base, side walls, end walls and atop opening.
 2. A container insert as recited in claim 1, wherein saidplastic backing sheet is heat welded to said insulation panels.
 3. Acontainer insert as recited in claim 2, wherein said plastic backingsheet comprises a thermoplastic film layer.
 4. A container insert asrecited in claim 1, wherein said end panels and side panels are spacedapart from said base panel of a distance approximately equal to thethickness of the base panel.
 5. A container insert as recited in claim1, further comprising a thermally insulated lid that is adapted to fitover the top opening.
 6. A container insert as recited in claim 1,wherein said plastic backing sheet comprises a plastic film that issubstantially impermeable to water vapor.
 7. A container insert asrecited in claim 1, wherein said plastic backing sheet comprises alaminate polymer structure.
 8. A container insert as recited in claim 7,wherein said plastic backing sheet comprises a thermoplastic film.
 9. Acontainer insert as recited in claim 1, wherein said insulation panelscomprise vacuum insulation panels.
 10. A container insert as recited inclaim 9, wherein said vacuum insulation panels comprise a core materialand a barrier film surrounding the core material, and wherein thebarrier film comprises a plastic film.
 11. A container insert as recitedin claim 10, wherein said barrier film consists essentially of polymericmaterials.
 12. A container insert as recited in claim 11, wherein saidbarrier film is a laminate film that comprises at least a first polymerfilm layer and a second polymer film layer.
 13. A container insert asrecited in claim 12, wherein said first polymer film layer comprisespolyethylene and said second polymer film layer comprises a materialselected from the group consisting of ethylene vinyl alcohol (EvOH),polyamide, polyethylene terephthalate (PET) and polyvinylidene chloride(PVDC).
 14. A container insert as recited in claim 1, further comprisingmeans for removably attaching said plastic backing sheet to an exteriorsurface of said end panels.
 15. A container insert as recited in claim14, wherein the attachment means comprises hook and loop fasteners. 16.A method for shipping a product, comprising the step of providing acontainer insert as recited in claim 1, placing the container insertwithin a shipping container, placing a product within the containerinsert, placing a lid on the container insert and transporting theshipping container to a desired location.
 17. A method as recited inclaim 16, further comprising cooling the product cavity defined by theshipping container insert.
 18. A container insert, comprising: a baseinsulation panel having an interior surface, an exterior surface and aperipheral edge surface; first and second side insulation panelstransversely disposed at opposite sides of the base panel to form sidewalls, each side panel having an interior surface, an exterior surfaceand a peripheral edge surface; first and second end insulation panelstransversely disposed at opposite ends of the base panel to form endwalls, each end panel having an interior surface, an exterior surfaceand a peripheral edge surface; and a plastic backing sheet disposedaround at least a portion of the exterior surfaces of the base panel,side panels and end panels; wherein the plastic backing sheet covers atleast a portion of the seams between the base panel and the side panelsand between the base panel and the end panels, and covers at least aportion of the seams between adjacent side panels and end panels suchthat the plastic backing sheet urges adjacent panels together along theseams.
 19. A container insert as recited in claim 18, wherein each ofsaid base panel, side panels and end panels is a vacuum insulationpanel.
 20. A container insert as recited in claim 18, wherein saidplastic backing sheet is a laminate polymer film comprising at leastfirst and second polymer layers.
 21. A container insert as recited inclaim 18, wherein said plastic backing sheet is heat welded to saidinsulation panels.